Installing the timing chain (Mazda CX-5KE)

Note:

: replace the part with a new one after each removal.

: use a special tool or device.

: places where sealant is applied.

: apply oil.

[Information copied from the portal: MAZBOOK.RU]



1. Make sure that the crankshaft key and dowel pin are positioned as shown in the figure. If the position of these elements is different from that shown in the figure, turn the crankshaft and balance shaft No.1 so as to set the piston of the first cylinder to the top dead center position.



2. Temporarily install the driven sprocket of the oil pump and tighten its mounting bolts.

3. Align the marked links of the oil pump drive chain with the timing mark of the balance shaft sprocket.



4. Install the oil pump drive chain with the balance shaft sprocket as one unit, aligning the timing marks on each sprocket with the marked links of the drive chain, as shown in the figure.



5. Tighten the balance shaft sprocket mounting bolt



6. Install the oil pump chain tensioner.

Caution: Do not remove the wire or rolled paper inserted into the oil pump chain tensioner housing at this stage.

7. Fix the flywheel ring gear using a special device.



8. Tighten the oil pump sprocket bolt to a torque of 20-30 Nm.

9. Tighten the balance shaft sprocket bolt to a torque of 38-46 Nm.

10. Remove the wire or rolled paper inserted into the oil pump chain tensioner housing and tension the drive chain. If a new chain tensioner is used, remove the inserted lock.

11. Install the timing drive sprocket onto the crankshaft.

12. Make sure that all timing marks and the crankshaft key are positioned as shown in the figure.

Note:

• The timing marks of the camshaft sprockets of the SKYACT/VG 2.5 engine are not completely parallel to the upper surface of the cylinder head.
• If the timing marks are not positioned as shown in the figure, turn the camshafts and crankshaft to set the piston of the first cylinder to the top dead center (TDC) position.

13. Install the drive chain damper No.2.



14. Install the timing chain, aligning the marks on the sprockets with the marked links of the chain, as shown in the figure.



15. Install the tensioner shoe.

16. Install the timing chain tensioner.

17. After installing the chain tensioner, remove the wire or rolled paper inserted into the tensioner housing and tension the drive chain. If a new chain tensioner is used, remove the inserted lock.



18. Install the timing chain damper No.1.

19. Make sure that the timing chain has no slack and recheck the location of the timing marks.

20. Turn the crankshaft two full revolutions and check the valve timing again.



21. For the new engine front cover, the two dowel pins shown in the picture protrude from the outside of the engine. Therefore, it is necessary to drive these dowel pins in with a hammer.




22. Remove oil, dirt and sealant residue from the contact surfaces of the front engine cover, cylinder head and cylinder block.

Note: The timing marks of the camshaft sprockets of the SKYACTIV-G 2.5 engine are not completely parallel to the top surface of the cylinder head.

Note: When reusing the front engine cover mounting bolts, remove any remaining locking compound from their threads.

Attention.

• Apply silicone sealant in an even, continuous strip.
• To prevent premature hardening of the silicone sealant, install the front cover on the engine within 10 minutes after applying the sealant. Tighten the mounting bolts immediately.
• Tightening a bolt with cured sealant may cause a crack in the cylinder head or cylinder block.

23. Apply silicone sealant as shown in the figure.





24. Apply sealant also to the areas shown in the following figure.

Caution: Apply silicone sealant so that it enters the cylinder head gasket.

25. Install the front cover on the engine.

Note:

• Temporarily install a suitable bolt into the hole of the automatic seat belt tensioner mounting bolt to prevent sealant from entering this hole. Use a 40 mm long M8x1.25 bolt for this purpose.
• Bolt #10 (the tightening sequence indicated below) must be installed with a new washer.

26. Tighten the front engine cover mounting bolts in the sequence shown in the figure to a torque of 20–26 Nm.

Note: replace the part with a new one after each removal.

27. Remove the bolt installed in the hole of the automatic tensioner mounting bolt.

28. Completely clean the contact surfaces of the cylinder block and oil pan from oil, sealant and other contaminants.

29. If the oil pan mounting bolts are reused, remove any remaining old sealant from them.



30. Apply silicone sealant to the oil pan from the inside of the bolt holes as shown in the figure. Sealant bead diameter: 3.0-7.0 mm.

Attention.

• Apply silicone sealant in a uniform, continuous bead around the entire perimeter of the oil pan.
• To prevent premature hardening of the silicone sealant, install the front cover on the engine within 10 minutes after applying the sealant. Tighten the mounting bolts immediately.
• Tightening a bolt with cured sealant may cause a crack in the cylinder head or cylinder block.

31. Install the oil pan onto the cylinder block and tighten the two bolts shown in the figure.



32. Tighten the oil pan mounting bolts in the sequence shown in the figure to a torque of 8-11 Nm.



33. Install new O-rings into the corresponding grooves of the front engine cover.

Caution: To prevent damage to the phase regulator electric drive, do not apply excessive force (100 N (10.2 kgf) or more) to the shaded areas in the figure.

Note:

• The eccentric shaft on the phase regulator side can rotate left and right.
• The phase regulator electric drive can be assembled with the eccentric shaft connecting groove located in any position. This does not affect the engine performance and does not cause any damage.

34. Before installation, turn the protrusion on the end of the phase regulator electric drive so that it coincides with the connecting groove on the phase regulator side.



35. Connect the protrusions with the connecting grooves of the electric phase regulator and tightly install the electric drive on the cylinder head. Tighten the mounting bolts with a torque of 20-26 Nm.

36. Install the crankshaft pulley and tighten the pulley bolt in two stages:

• Stage 1: 90-110 Nm.
• Step 2: Pull to an angle of 55-65°.

37. Install the water pump pulley and tighten the bolt.

38. Align the hole in the pulley with the hole in the water pump housing as shown in the figure.

Caution: Be careful not to damage the grooves and surfaces of the water pump pulley when using tools, otherwise it may cause increased wear and damage to the drive belt, abnormal noise during operation, and damage to the pulley and rust.

39. Insert a suitable 70mm long bolt into the water pump hole as shown in the figure to fix the water pump pulley from turning. Fully tighten the water pump pulley bolt to a torque of 8-11 Nm.



40. Remove the bolt inserted to prevent the water pump pulley from turning.

41. Install the oil spray tubes and tighten the mounting bolts in the sequence shown in the figure.

Attention.

• To ensure the tightness of the cylinder head cover, the following must be observed:
• Make sure that the cylinder head cover gasket is inserted into the cover groove and install the cylinder head cover.
• Remove oil, dirt and sealant residue from contact surfaces.
• To prevent premature hardening of the silicone sealant, install the cylinder head cover on the engine within 10 minutes after applying the sealant and immediately tighten the mounting bolts.

42. Insert a new cylinder head gasket into the groove of the cylinder head cover.

43. Apply silicone sealant to the areas shown in the figure.



44. Tighten the cylinder head cover bolts in the sequence shown in the figure to a torque of 4.5-7.0 Nm.



45. Subsequent installation is carried out in the reverse order of removal.